Digital image-paper registration error correction through image shear

ABSTRACT

A method, non-transitory computer readable medium and apparatus for applying an image shear to correct a digital image-paper registration error are disclosed. For example, the method, performed by a processor of a printing device, includes detecting an amount of skew of a paper traveling through a registration system of a printing device, determining that the amount of skew is greater than a predefined threshold, applying an image shear to a digital image that will be printed on the paper, and controlling a plurality of printheads of the printing device to print the digital image on the paper with the image shear that is applied.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.15/948,626, filed Apr. 9, 2018, which was recently allowed, which isherein incorporated by reference in its entirety.

The present disclosure relates generally to registration errors inprinting devices and, more particularly, to a method and apparatus forperforming image shear to correct a digital image-paper registrationerror.

BACKGROUND

Printing devices can be used to print images on print media. The printmedia can be fed through the printing device along a transport path andimaging path to have the image printed. Along the transport path and theimaging path, there are certain locations where processing errors canoccur that can cause a misalignment of the image relative to the printmedia.

For example, the printing devices can have a registration system. Theregistration system may be responsible for correctly feeding the printmedia to an imaging system such that the printed image is correctlyaligned with the print media. As the size and weight of print mediagrows larger and larger, it can be more and more difficult for currentlydesigned registration systems to handle the larger print media.

SUMMARY

According to aspects illustrated herein, there are provided a method,non-transitory computer readable medium and apparatus for applying animage shear to correct a digital image-paper registration error. Onedisclosed feature of the embodiments is a method, performed by aprocessor of a printing device, that detects an amount of skew of apaper traveling through a registration system of a printing device,determines that the amount of skew is greater than a predefinedthreshold, applies an image shear to a digital image that will beprinted on the paper, and controls a plurality of printheads of theprinting device to print the digital image on the paper with the imageshear that is applied.

Another disclosed feature of the embodiments is a non-transitorycomputer-readable medium having stored thereon a plurality ofinstructions, the plurality of instructions including instructionswhich, when executed by a processor, cause the processor to performoperations that detect an amount of skew of a paper traveling through aregistration system of a printing device, determine that the amount ofskew is greater than a predefined threshold, apply an image shear to adigital image that will be printed on the paper, and controls aplurality of printheads of the printing device to print the digitalimage on the paper with the image shear that is applied.

Another disclosed feature of the embodiments is an apparatus comprisinga processor and a computer-readable medium storing a plurality ofinstructions which, when executed by the processor, cause the processorto perform operations that detect an amount of skew of a paper travelingthrough a registration system of a printing device, determine that theamount of skew is greater than a predefined threshold, apply an imageshear to a digital image that will be printed on the paper, and controlsa plurality of printheads of the printing device to print the digitalimage on the paper with the image shear that is applied.

BRIEF DESCRIPTION OF THE DRAWINGS

The teaching of the present disclosure can be readily understood byconsidering the following detailed description in conjunction with theaccompanying drawings, in which:

FIG. 1 illustrates a block diagram of example printing device of thepresent disclosure;

FIG. 2 illustrates an example of a digital image-paper registrationerror of the present disclosure;

FIG. 3 illustrates a block diagram of image shear of the presentdisclosure;

FIG. 4 illustrates a flowchart of an example method for applying animage shear to correct a digital image-paper registration error of thepresent disclosure; and

FIG. 5 illustrates a high-level block diagram of an example computersuitable for use in performing the functions described herein.

To facilitate understanding, identical reference numerals have beenused, where possible, to designate identical elements that are common tothe figures.

DETAILED DESCRIPTION

The present disclosure is related to a method and apparatus to correctdigital image-paper registration errors through image shear. Asdiscussed above, printing devices can have a registration system. Theregistration system may be responsible for correctly feeding the printmedia to an imaging system such that the printed image is correctlyaligned with the print media. As the size and weight of print mediagrows larger and larger, it can be more and more difficult for currentlydesigned registration systems to handle the larger print media.

Some systems attempt to remove registration errors by mechanicallymoving the paper to be properly aligned to the image path. For example,the systems may rotate the print media to remove skew such that theprinted image is aligned with the print media. In other words, alignmentmay be defined as the borders or edges of the printed image beingparallel to the edges of the print media.

Mechanical solutions may have limits to the length or size of paper thatcan be properly handled. In addition, mechanical solutions may not beadequate in certain scenarios where the printing device may have tohandle various different sized print media.

Embodiments of the present disclosure use an image shear to correct adigital image-paper registration error. In other words, rather thanmechanically adjusting the print media, the present disclosure applies adigital solution to adjust the printed image on print media that mayhave been skewed when passing through the image path. In one embodiment,the digital solution of the present disclosure may be applied inaddition to mechanical solutions to correct registration errors.

FIG. 1 illustrates a block diagram of an example printing device 100 ofthe present disclosure. The printing device 100 may be any type ofprinting device such as a multi-function device (MFD), a copy machine,laser printer, an ink jet printer, and the like.

In one embodiment, the printing device 100 may include a registrationsystem 102, a digital front end (DFE) 104, and a printing system 106. Itshould be noted that the printing device 100 has been simplified forease of explanation in FIG. 1 and may include additionalcomponents/systems that are not shown. For example, the printing device100 may also include a feed tray, a finishing module, transport pathcomponents, a duplex return path, and the like.

In one embodiment, the registration system 102 may include at least onesensor 108. The sensor 108 may be a charged coupled device (CCD) sensor,a capacitive sensor, a video camera sensor, and the like. The sensor 108may detect a position of a paper that enters the registration system 102for printing. In one embodiment, the position may refer to an amount ofskew of the paper. The amount of skew may be defined as an angle ofmisalignment relative to a process direction. When the paper is skewed,an image-paper registration error may occur during printing of a digitalimage.

FIG. 2 illustrates an example of the image-paper registration error. Forexample, a paper 202 may be skewed when leaving the registration system102 towards the printing system 106 in a process direction 208. FIG. 2illustrates a skew angle 228 that measures an amount of skew relative tothe process direction 208. In one example, the skew angle 228 may bemeasured in milliradians.

In one embodiment, when the paper 202 is skewed, digital images 204 and206 that are printed onto the paper 202 may be misaligned with the paper202 creating the image-paper registration error. In some instances, theimage-paper registration error may be unnoticeable. However, when theskew of the paper 202 is large enough the image-paper registration errormay be noticeable.

For example, in FIG. 2, an edge 212 of the images 204 and 206 may not beparallel to an edge 210 of the paper 202. In addition, an edge 214 ofthe images 204 and 206 may not be parallel to an edge 216 of the paper202. Said another way, a distance 218 between the edges 212 and 210 onthe right hand side of the paper 202 may be less than a distance 220between the edges 212 and 210 on the left hand side of the paper 202, orvice versa. In addition, a distance 222 between the edges 214 and 216 atthe top of the paper 202 may be greater than a distance 224 between theedges 214 and 216 at the bottom of the paper 202, or vice versa.

As noted above, some printing devices attempt to correct the image-paperregistration error via mechanical designs to control the alignment ofthe paper 202. However, the mechanical solutions may not be efficient orfast enough, or may be unable to correct the image-paper registrationerrors if the paper 202 is too large or long. However, the presentdisclosure applies a digital correction to the digital image 204 and/or206 to correct the image-paper registration error using various modulesin the DFE 104.

Referring back to FIG. 1, in one embodiment, the DFE 104 may include aprocessor 110, a memory 112, a pre-shear module 114, an image shearmodule 116, and a post-shear module 118. In one embodiment, theprocessor 110 may be coupled to the sensor 108, the memory 112, thepre-shear module 114, the image shear module 116, the post-shear module118, and printheads 120 in the printing system 106.

The processor 110 may receive the amount of skew detected by the sensor108. The processor 110 may the control operations of the pre-shearmodule 114, the image shear module 116, the post-shear module 118, andthe printheads 120 to correct the image-paper registration error basedon the amount of skew that was detected. The processor 110 may executeinstructions stored in the memory 112. The memory 112 may also be usedas a buffer to temporarily store pixel and scanline information duringthe image shear process, as discussed in further details below.

In one embodiment, the pre-shear module 114 may perform variouspre-shear processes on the digital image (e.g., the digital images 204and/or 206). The pre-shear module 114 may include different componentsor instructions executed by the processor 110 to perform operations suchas edge growth, line width control, color correction, and the like. Inother words, although the pre-shear module 114 is illustrated as asingle block in FIG. 1, the pre-shear module 114 may be comprised of aplurality of different modules or components that each perform adifferent pre-shear process.

In one embodiment, the image shear module 114 may include instructionsexecuted by the processor 110 to perform operations to apply image shearto the digital image. The image shear may be applied in the processdirection, in a cross-process direction, or in both the process and thecross-process direction.

In one embodiment, image shear may include shifting of scanlines orblocks of pixels to gradually shift the digital image in a directionthat compensates for the amount of skew in the paper. In other words, ifthe paper was skewed by 1.0 milliradians in the inboard direction, theimage shear may attempt to shift the digital image gradually by 1.0milliradians in the inboard direction such that the edges of the digitalimage and the paper are parallel or aligned.

In some instances, when the image shear is only applied in thecross-process direction, the lateral edges (e.g., the edges 210 of thepaper 202 and the edges 212 of the digital images 204 and 206) may becorrected. However, the leading and trail edges (e.g., the edges 216 ofthe paper 202 and the edges 214 of the digital images 204 and 206) mayremain misaligned. In other words, applying image shear is not the sameas simply rotating the image to correct the alignment between thedigital image that is printed and the paper.

As discussed above, the image shear may be applied in the cross-processdirection. In one embodiment, the image shear in the cross-processdirection may shift a number of vertical scanlines in the skew directionby one pixel size. In one embodiment, the number of vertical scanlinesmay be based on the amount of skew. For example, if the amount of skewis detected by the sensor 108 to be 0.5 milliradians, every 2000vertical scanline blocks may be shifted in the skew direction by onepixel. In one embodiment, the vertical scanlines may be shifted in asimple step pixel shift or may be shifted gradually.

FIG. 3 illustrates examples of the cross-process direction image shear.In FIG. 3, an original digital image 302 may have vertical scanlines 310₁ to 310 _(n) (also referred to herein individually as a verticalscanline 310 or collectively as vertical scanlines 310) and horizontalscanlines 314 ₁ to 314 _(m) (also referred to herein individually as ahorizontal scanline 314 or collectively as horizontal scanlines 314).Each vertical scanline may be comprised of pixels 312 ₁ to 312 _(m)(also referred to herein individually as a pixel 312 or collectively aspixels 312).

It should be noted that FIG. 3 is intended to illustrate an originaldigital image 302 have any number of vertical scanlines 310, horizontalscanlines 314, and pixels 312. Thus, although it appears that theoriginal image 302 is comprised of an 8×8 pixel block, it should benoted that it is not so limited. In addition, any numerical examplesdescribed herein may not be intended to necessarily reflect an 8×8 pixelblock such as that illustrated in FIG. 3.

In one embodiment, a simple step pixel shift 304 may comprise shiftingthe number of vertical scanlines based on the amount of skew in a singlestep. For example, as illustrated in FIG. 3, the simple step pixel shift304 may shift four vertical scanlines at a time by one pixel size. Thus,the vertical scanlines 310 ₁ to 310 ₄ may be shifted together in asingle step.

In one embodiment, a gradual pixel shift 306 may include shifting thenumber of vertical scanlines gradually such that the image shear is lessnoticeable. For example, the vertical scanline 310 ₁ may be shifted a bya full pixel size. The vertical scanline 310 ₂ may be shifted by threefourths of a pixel size. The vertical scanline 310 ₃ may be shifted byhalf of a pixel size. The vertical scanline 310 ₄ may be shifted by aquarter of a pixel size, and so forth. In one embodiment, the amount ofshift may be the size of the pixel 312 divided by a number of verticalscanlines that is shifted based on the amount of skew.

In one embodiment, whether the image shear module 116 applies the simplestep pixel shift 304 or the gradual pixel shift 306 may bepredetermined. In one embodiment, the type of pixel shift that isapplied may be based on a printing resolution and a particular stage ofdigital image processing along the digital image path (e.g.,halftone/binary image processing path or contone image path). Forexample, for high resolution printers the simple step pixel shift 304may be applied and for low resolution printers the gradual pixel shift306 may be applied. In addition, the simple step pixel shift 304 may beapplied for either halftone or contone image processing, whereas thegradual pixel shift 306 may be applied only for contone printing.

The simple step pixel shift 304 may be faster and consume less memoryand processing resources than the gradual pixel shift 306. However, thesimple step pixel shift 304 may be more noticeable than the gradualpixel shift 306. The number of vertical scanlines that are shifted maybe variable depending on the amount of skew that is detected by thesensor 108.

In one embodiment, the post shear module 118 may apply a missing jetprocess to the digital image after the image shear is applied in thecross-process direction. The missing jet process may be a process thatis applied to some printing devices (e.g., ink jet printers) tocompensate for missing jets.

For example, if an ink jet printer prints at 1000 dots per inch, the inkjet printer may have 1000 ink jets per inch that are responsible fordropping a dot of ink at each respective location along thecross-process direction. The ink jet printer may detect if an ink jet isnot firing at a particular location (e.g., the ink jet may be clogged).For example, if the ink jet printer detects that ink jet number 97 inthe cross-process direction is not firing, the ink jet printer maydispense additional ink via the adjacent ink jets (e.g., ink jet number96 and 98) to compensate for the missing dot from the ink jet number 97.

However, if the missing jet process were to be applied to the digitalimage before the image shear was applied to the digital image, then themissing jet process may compensate at the wrong locations due to theshifting of the vertical scanlines 310, as described above. Thus, thepresent disclosure ensures that the image shear in the cross-processdirection is applied before the missing jet process is applied.

In one embodiment, the post-shear module 118 may also apply image shearin the process direction. However, it should be noted that the imageshear in the process direction may also be executed by the image shearmodule 116.

In one embodiment, the image shear in the process direction may beoptional. In one embodiment, the image shear in the process directionmay shift a number of horizontal scanlines 314 in the process directionto adjust for the image-paper registration error in the processdirection. In other words, the image shear in the process direction mayalign the edges 214 of the digital images 204 and 206 to the edges 216of the paper 202, illustrated in FIG. 2.

In one embodiment, the number of horizontal scanlines 314 that isshifted may be a function of the amount of skew. In one example, thefunction may comprise a resolution times a width of the paper times theamount of skew. For example, for 1 milliradian ( 1/1000 radians) at 1200dots per inch resolution for a 14 inch wide paper, a total shift ofabout 17 pixels across the image width may be applied.

In one example, the image shear in the process direction may shift“blocks” of pixels 312. In one embodiment, the block size may be theinverse of the amount of skew. So using the example above of 1milliradians, the inverse of 1/1000 radians would be 1000 pixels. As aresult, we would need to shift every block of 1000 pixels by 1 pixel toachieve a total amount of shear of 17 pixels across the width of 14inches in the process direction. Said another way, the image shear inthe process direction may include a number of vertical scanlines in thecross-process direction and the number of horizontal scanlines in theprocess direction.

Referring back to FIG. 1, in one embodiment, the image shear module 116and/or the post-shear module 118 may be activated if the amount of skewis greater than a predefined threshold. For example, some amount of skewmay not be noticeable. In one example, the predefined threshold may be0.1 milliradians of skew, 0.5 milliradians of skew, 1 milliradian ofskew, and the like. The amount of skew detected by the sensor 108 may becompared to the predefined threshold. If the amount of skew is greaterthan the predefined threshold, then the processor 110 may execute theimage shear module 116 and/or the post-shear module 118.

In one embodiment, the printing system 106 may include the printheads120. The printheads 120 may be inkjet printheads, toner basedimaging/development sub-systems, and the like. The printheads 120 maydispense any printing fluid to print the digital images 204 and 206 onthe paper 202. In one embodiment, after the image shear is applied tothe digital image, the processor 110 may control the printheads 120 inthe printing system 106 to print the digital images 204 and 206 with theimage shear applied onto the paper 202. As a result, the digital images204 and 206 may be properly aligned with the paper 202 and theimage-paper registration error may be removed or eliminated.

Thus, the printing device 100 of the present disclosure may correct theimage-paper registration error by applying an image shear, rather thanusing a mechanical solution to adjust a position of the paper 202. Thepresent disclosure may provide more efficient corrections forimage-paper registration errors.

FIG. 4 illustrates a flowchart of an example method 400 for correctingan image-paper registration error. In one embodiment, one or more stepsor operations of the method 400 may be performed by the printing device100, or a computer/processor as illustrated in FIG. 5 and discussedbelow.

At block 402, the method 400 begins. At block 404, the method 400detects an amount of skew of a paper traveling through a registrationsystem of a printing device. In one embodiment, the amount of skew maybe detected by a sensor in the registration system. For example thesensor may detect if both sides of a leading edge of the paper cross thesensor at the same time. If the opposite sides of the leading edge crossthe sensor at different times, the sensor may calculate an amount ofskew, in milliradians, based on the difference in time each side of theleading edge crossed the sensor.

At block 406, the method 400 determines that the amount of skew isgreater than a predefined threshold. The amount of skew may betransmitted to a processor that can then compare the amount of skew to apredefined threshold. If the amount of skew is greater than or equal tothe predefined threshold, an image shear may be applied to the digitalimage that is to be printed on the paper.

At block 408, the method 400 applies an image shear to a digital imagethat is to be printed on the paper. In one embodiment, the image shearmay be applied in a cross-process direction, as described above. Itshould be noted that the image shear in the cross-process direction isapplied before a missing jet process is applied, if applicable.

In one embodiment, the image shear may also be applied in a processdirection, as described above. The image shear in the process directionmay be applied before or after the missing jet process is applied, ifapplicable.

At optional block 410, the method 400 applies a missing jet process tothe digital image after the image shear is applied. As discussed above,the missing jet process may compensate for ink jets that fail to fire inan ink jet printer. The missing jet process, if applied, may be appliedonly after the image shear in the cross-process direction is applied. Asnoted above, in some embodiments, the image shear in the processdirection may be applied after the missing jet process is applied.

At block 412, the method 400 controls a plurality of printheads of theprinting device to print the digital image on the paper with the imageshear that is applied. For example, the printheads may dispense ink inaccordance with the processed digital image with the image shear that isapplied. As a result, the digital image may be printed such that atleast the lateral edges of the digital image and the paper are aligned,or parallel.

In other words, if the image shear is not applied in the processdirection, the leading edge and trail edge of the digital image may notbe aligned, or parallel with, the leading edge and trail edge of thepaper. Said another way, the image shear that is applied in the presentdisclosure is not simply rotating the digital image to align the digitalimage with the paper. At block 414, the method 400 ends.

It should be noted that the blocks in FIG. 4 that recite a determiningoperation or involve a decision do not necessarily require that bothbranches of the determining operation be practiced. In other words, oneof the branches of the determining operation can be deemed as anoptional step. In addition, one or more steps, blocks, functions oroperations of the above described method 400 may comprise optionalsteps, or can be combined, separated, and/or performed in a differentorder from that described above, without departing from the exampleembodiments of the present disclosure.

FIG. 5 depicts a high-level block diagram of a computer that isdedicated to perform the functions described herein. As depicted in FIG.5, the computer 500 comprises one or more hardware processor elements502 (e.g., a central processing unit (CPU), a microprocessor, or amulti-core processor), a memory 504, e.g., random access memory (RAM)and/or read only memory (ROM), a module 505 for correcting animage-paper registration error, and various input/output devices 506(e.g., storage devices, including but not limited to, a tape drive, afloppy drive, a hard disk drive or a compact disk drive, a receiver, atransmitter, a speaker, a display, a speech synthesizer, an output port,an input port and a user input device (such as a keyboard, a keypad, amouse, a microphone and the like)). Although only one processor elementis shown, it should be noted that the computer may employ a plurality ofprocessor elements.

It should be noted that the present disclosure can be implemented insoftware and/or in a combination of software and hardware deployed on ahardware device, a computer or any other hardware equivalents (e.g., theprinting device 100). For example, computer readable instructionspertaining to the method(s) discussed above can be used to configure ahardware processor to perform the steps, functions and/or operations ofthe above disclosed methods. In one embodiment, instructions and datafor the present module or process 505 for correcting an image-paperregistration error (e.g., a software program comprisingcomputer-executable instructions) can be loaded into memory 504 andexecuted by hardware processor element 502 to implement the steps,functions or operations as discussed above in connection with theexample method 400. Furthermore, when a hardware processor executesinstructions to perform “operations,” this could include the hardwareprocessor performing the operations directly and/or facilitating,directing, or cooperating with another hardware device or component(e.g., a co-processor and the like) to perform the operations.

The processor executing the computer readable or software instructionsrelating to the above described method(s) can be perceived as aprogrammed processor or a specialized processor. As such, the presentmodule 505 for correcting an image-paper registration error (includingassociated data structures) of the present disclosure can be stored on atangible or physical (broadly non-transitory) computer-readable storagedevice or medium, e.g., volatile memory, non-volatile memory, ROMmemory, RAM memory, magnetic or optical drive, device or diskette andthe like. More specifically, the computer-readable storage device maycomprise any physical devices that provide the ability to storeinformation such as data and/or instructions to be accessed by aprocessor or a computing device such as a computer or an applicationserver.

It will be appreciated that variants of the above-disclosed and otherfeatures and functions, or alternatives thereof, may be combined intomany other different systems or applications. Various presentlyunforeseen or unanticipated alternatives, modifications, variations, orimprovements therein may be subsequently made by those skilled in theart which are also intended to be encompassed by the following claims.

What is claimed is:
 1. A method for correcting an image-paperregistration error, comprising: detecting, by a processor, an amount ofskew of a paper traveling through a registration system of a printingdevice; determining, by the processor, that the amount of skew isgreater than a predefined threshold; applying, by the processor, animage shear to a digital image that is to be printed on the paper; andprinting, via a plurality of printheads controlled by the processor, thedigital image on the paper with the image shear that is applied.
 2. Themethod of claim 1, further comprising: applying, by the processor, amissing jet process to the digital image after the image shear isapplied.
 3. The method of claim 1, wherein the image shear is applied ina cross-process direction.
 4. The method of claim 3, wherein a number ofvertical scanlines that the image shear is applied to is based on theamount of skew.
 5. The method of claim 4, wherein the image shear isapplied to the number of vertical scanlines in a simple step pixelshift.
 6. The method of claim 4, wherein the image shear is applied tothe number of vertical scanlines in a gradual pixel shift.
 7. The methodof claim 1, wherein the image shear is applied in a process direction.8. The method of claim 7, wherein the image shear is applied to a numberof horizontal scanlines calculated based on a function of the amount ofskew.
 9. The method of claim 8, wherein the function comprises aresolution of the digital image times a width of the digital image timesthe amount of skew.
 10. The method off claim 1, wherein the image shearis applied in a cross-process direction and a process direction using ablock of pixels.
 11. A non-transitory computer-readable medium storing aplurality of instructions, which when executed by a processor, cause theprocessor to perform operations for correcting an image-paperregistration error, the operations comprising: detecting an amount ofskew of a paper traveling through a registration system of a printingdevice; determining that the amount of skew is greater than a predefinedthreshold; applying an image shear to a digital image that will beprinted on the paper; and printing the digital image on the paper withthe image shear that is applied.
 12. The non-transitorycomputer-readable medium of claim 11, further comprising: applying amissing jet process to the digital image after the image shear isapplied.
 13. The non-transitory computer-readable medium of claim 11,wherein the image shear is applied in a cross-process direction.
 14. Thenon-transitory computer-readable medium of claim 13, wherein a number ofvertical scanlines that the image shear is applied to is based on theamount of skew.
 15. The non-transitory computer-readable medium of claim14, wherein the image shear is applied to the number of verticalscanlines in a simple step pixel shift.
 16. The non-transitorycomputer-readable medium of claim 14, wherein the image shear is appliedto the number of vertical scanlines in a gradual pixel shift.
 17. Thenon-transitory computer-readable medium of claim 11, wherein the imageshear is applied in a process direction.
 18. The non-transitorycomputer-readable medium of claim 16, wherein the image shear is appliedto a number of horizontal scanlines calculated based on a function ofthe amount of skew.
 19. The non-transitory computer-readable medium ofclaim 18, wherein the function comprises a resolution of the digitalimage times a width of the digital image times the amount of skew. 20.The non-transitory computer-readable medium of claim 11, wherein theimage shear is applied in a cross-process direction and a processdirection using a block of pixels.